Reusable footing form accessories

ABSTRACT

An accessory kit for reusable footing forms ( 1001, 1002 ) used in conjunction with insulated concrete forms or steel panel wall forms. The kit includes an inside corner mold ( 500 ) and an inside corner form ( 600 ) that attach to the footing forms ( 1001, 1002 ). The inside corner molds are secured by slotted fasteners ( 410, 440 ) that are adjustably positioned and fastened by wedge bolts ( 400 ). The kit also includes outside corner molds ( 100, 200 ) that is adjustable to accommodate a variety of final wall configurations. An adjustment lever ( 600 ) is provided to assist in positioning two abutting footing forms ( 1001 ).

FIELD OF THE INVENTION

This invention relates generally to the field of cast in place construction techniques, and more particularly to reusable steel footing forms that act as a mold into which concrete or other structural material is poured.

BACKGROUND OF THE INVENTION

Footings for buildings have been constructed from a wide range of materials including boulders, cobbles, crushed rock, and concrete. The purpose of the footing is to provide a wide base with sufficient strength to support the vertical walls that extend above each footing. Depending on soil types and climate, footings vary in size and composition to accommodate the desired building and conditions.

Concrete footings have typically been poured to include imbedded reinforcing steel. Wooden planks and stakes are used to create a mold within which the concrete footing is formed. After the concrete has been cast and cured, the wood is removed, often resulting in destruction of the wood. Walls are then constructed on top of the footings. If concrete walls are to be poured on top of the cured footings, a second mold setup and concrete pour is required.

Steel footing forms have been used to create concrete footings that permit walls and footings to be poured simultaneously. Numerous logistical problems are common with existing steel footing molds. Assembly is time consuming, and achieving the desired wall length can be problematic. Maintaining the desired dimension, shape and orientation requires that the construction crew perform numerous repetitive steps, consuming time and introducing the possibility for error.

Existing devices utilize corner forming structures that were fastened with steel stakes or sometimes with threaded fasteners that eventually fail, thereby introducing errors and requiring greater skill on the part of the user. U.S. Pat. No. 6,332,599, entitled FOOTING FORMS FOR CONCRETE MONOLITH CONSTRUCTION, discloses the use of corner forms that are secured by long tie bolts placed inside of sleeves.

SUMMARY OF THE INVENTION

The present invention is a reusable integrated footing and wall mold form. The invention is usable with both insulated concrete form construction and with concrete walls constructed with reusable wall panel forms. The invention includes an inside corner accessory that allows the present steel footing form to work with the traditional wall panel forms. The inside corner accessory seals off holes that otherwise allow liquid concrete to escape from the mold structure at the transition point between steel footing form and steel wall panel form, thereby permitting wall panel forms to be poured simultaneously with the steel formed footings.

The present invention uses a method to join the various straight and corner steel footing mold parts that is compatible with existing wall panel form fasteners. All bolts used to connect steel footing form parts are secured with commonly available wedge bolts. The wedge bolts simplify the securing of footing forms when compared to threaded fasteners, and are adjustable to accommodate various wall thicknesses. Each bolt is contained within a small diameter tube that is cut to the width of and remains embedded in the cast concrete. The tube allows the bolt to be removed and reused.

The present invention includes corner forms and related accessories that are assembled with convex head slotted bolts secured with wedge bolts. The convex head is cast into the concrete and is easily removed as the convex end offers almost no gripping surface and is only cast approximately one quarter of an inch into the concrete footing. The slotted bolts can be inserted through an array of holes that allow for exact bolt placement and the construction of any common wall thickness.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of outside corner forms and an inside corner form constructed according to the principles of the present invention attached to a reusable wall form;

FIG. 2 is an end elevation of a cast concrete monolith produced by the reusable wall forms illustrated in FIG. 1;

FIG. 3 is a side elevation of a slotted shaft and wedge bolt as utilized by the wall forms depicted in FIG. 2;

FIG. 4 is an end elevation of a cast concrete monolith with an insulated concrete form in place;

FIG. 5 is a perspective view of a first inside corner form constructed according to the principles of the present invention;

FIG. 6 is a perspective view of a second inside corner form constructed according to the principles of the present invention;

FIG. 7 is an exploded perspective view of an outside corner form constructed according to the principles of the present invention;

FIG. 8 is a top plan view of a footing form constructed according to the principles of the present invention;

FIG. 9 is a perspective view of a footing form adjustment lever constructed according to the principles of the present invention; and

FIG. 10 is a perspective view of the footing form adjustment lever as illustrated in FIG. 9 shown in an engaged relationship with two steel footing forms constructed according to the principles of the present invention.

FIG. 11 is a perspective view of the inside corner form for insulated concrete forms and the outside corner form with an insulated concrete form resting on them.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 illustrates outside corner forms 100, 200, and 300 attached to footing forms 1001, 1002. The footing forms 1001, 1002 are substantially identical to the type illustrated and described in the previously mentioned U.S. Pat. No. 6,332,599. Outside corner forms 100 and 200 perform the function of closing the footing forms so concrete may be poured without leakage. The corner forms also perform a second function of anchoring building corners within necessary close tolerances to achieve building accuracy. Form 100 and 200 are identical except for the placement of holes 145, 170, 245, 270 and the presence or absence of tabs 155. When 100 and 200 are connected to one another at edges 105 and 205, tabs 155 overlap onto surfaces 210, 220, 230 so holes 145 and 170 line up with holes 245 and 270 and are fastened with convex bolt 440. Outside corners may be built to make 45, 90 or other degrees

As seen in FIG. 7, each of the outside corner forms 100 and 200 includes a base vertical extension, 110 and 210 respectively, upon which a standard lumber such as a 2×4 160, 260 may be attached. Lumber 160, 260 provide an anchor point on forms 100 and 200 to which stakes or other such devices can be attached with screws or nails to hold forms 100 and 200 at a desired level and position with respect to the ground surface. A simple linear bend which may be formed by a common metal brake tool forms the junctions 115 and 215 between vertical extensions 110, 210 and the sloping side walls 120, 220. The slope angle 225 reduces concrete volume, allows for easy removal from cast concrete and must match the angle 1007 of the forms 1001, 1002 for easy, seamless assembly.

The sloping side walls 120, 220 terminate by means of a simple lineal bend 180, 280 located at the upper vertical extension 130, 230 which is approximately at the exterior edge 940, 945 of the wall panel forms 910, 915. The forms 910, 915 may be forms such as the Symons™ wall panel forms manufactured by the Dayton Superior Corporation 7777 Washington Village Dr., Suite 130, Dayton, Ohio 45459. The wall panel forms 910, 915 remain in place only until contained liquid concrete 930 hardens around reinforcement steel 920 to form wall 950. The exterior edge 940, 945 of wall panel form 910, 915 lands approximately in line with the exterior edge 805, 810 of a common insulated concrete form 801, 802 which remains in place with the concrete wall. Support ledges 150, 250 consisting of lineal bends 185, 285 serve to support vertically extending wall panel forms 910, 915 or insulated concrete forms 801, 802. Short vertical lips 140, 240 extend above ledges 150, 250 approximately one inch to hold the wall panel forms 910, 915 or insulated concrete forms 801, 802 in place on the ledges 150, 250. Between wall panel forms 910 and 915 as well as between corner forms 100, 200 and opposing sides of straight forms 1001, 1002, there is a space 1050 which will in the preferred embodiment be filled with concrete 930, reinforcement steel 920 or other suitable construction materials.

Holes 145 and 170 are located on tabs 155 bent at a desired angle, usually ninety degrees, to fasten corner form 100 to corner form 200 through holes 245, 270 using convex head slot bolt 440. Convex head slot bolt 440 is held in place using an industry standard wedge bolt 400 commonly used to secure wall panel forms. Sets of holes 135, 235 secure corner forms 100, 200 to straight forms 1001, 1002. Holes for fastening corner forms may be designed round, square or rectangular so fastening can be accomplished with a variety of slotted bolts or wedge bolts. Several holes are provided to accommodate various common wall thicknesses such as 6 inch or 8 inch, as well as to accommodate the widths of various insulated concrete forms 801, 802 currently for sale in lumber and construction stores.

FIG. 5 illustrates inside corner form 500 for use with insulated concrete forms 801, 802. Corner form 500 is comprised of two mirror image identical parts 580, 590 joined by overlapping tabs 540 typically spot welded together. Base vertical extensions 510, 515 which form the wider portion 960 of the resulting concrete footing 900 are joined at a simple linear bend 570, 575 to sloping side walls 520, 525. The slope angle 585 must match the angle of straight forms 1001, 1002 for easy, seamless assembly. Sloping side walls 520, 525 terminate at approximately the exterior faces 805, 810 of insulated concrete forms 801, 802 where a linear bend 522 leads to upper vertical extensions 530, 535. Extending perpendicular to the face of 530 and 535 at point 1060 aligned with straight form 1001, 1002 ledges are tabs 550, 560. The tabs 550, 560 serve to prevent concrete from leaking through the straight form ledge channel 1060 when the walls 950 and footings 900 are filled with concrete. Significant volumes of low viscosity concrete may leak thru holes approximately ¼″ or larger if not blocked off or plugged by some material or device such as 550, 560.

Holes 542, 545 are placed to provide a maximum strength connection to straight form 1001, 1002. Inside corner form 500 is secured to straight forms using convex head slot bolt 440. Convex head slot bolt 440 is held in place using an industry standard wedge bolt 400 commonly used to secure wall panel forms.

FIG. 6 illustrates inside corner form 300 for use with wall panel forms 910, 915. Corner form 300 is comprised of two mirror image identical parts 360, 370 joined by overlapping tabs 350 that are typically spot welded together. Base vertical extensions 305, 315 which form the wider portion 960 of the resulting concrete footing 900 are joined at a simple linear bend 312, 317 to sloping side walls 320, 325. The slope angle 322 must match the angle 1007 of 1001, 1002 for easy, seamless assembly. Sloping side walls 320, 325 terminate approximately at the exterior faces 940, 945 of wall panel forms 910, 915 where a simple lineal bend 323, 327 leads to upper vertical extension 330, 335. Upper vertical extension 330, 335 ends at a linear bend 352, 357 leading to horizontal ledges 340, 343 which serve to support the wall panel forms 910, 915 as well as contain concrete that would otherwise leak at this point 1008.

Holes 305, 345 are placed to provide a maximum strength connection to straight form 1001, 1002. Inside corner form 300 is secured to straight forms 1001, 1002 using convex head slot bolt 440. Convex head slot bolt 440 is held in place using an industry standard wedge bolt 400 commonly used to secure wall panel forms in the concrete construction industry. Inside corners may be manufactured to make 90, 45 or other degree corners if desired.

FIG. 3 illustrates the preferred embodiment of slotted bolts 410, 440 that serve to fasten footing forms 1001 and 1002 securely together. Slotted bolt 410 is a long rod typically made of steel that slides through straight footing forms 1001, 1002 and associated spacer tubes 1003. Sets of holes 415 allow for variation in the width 1004 of the footings by placing pin 405 in desired hole. Slot 420 on the other end of bolt 410 provides a fastening point to secure the bolt tightly in place by placing industry standard wedge bolt 400 into slot 420 and pressing the bolt 400 tightly against upper and lower vertical sections 1032, 1033 of straight forms 1001, 1002. After the concrete in the footings 900 and walls 950 has hardened, the wedge bolts 400 are easily tapped out of the slotted bolts 410 with a hammer and the slotted bolts subsequently tapped out of the straight footing forms 1001, 1002 for later reuse.

Convex head slotted bolt 440 serves to secure outside corners 100, 200 together as well as to secure outside corners 100, 200 and inside corners 300, 500 to straight forms 1001, 1002. Convex head slotted bolt 440 is placed through holes 145, 170, 245, 270, 305, 345, 135, 235 on corner forms 100, 200, 300, 500 and or straight forms 1001, 1002 to create desired footing configuration. Wedge bolt 400 is then placed in slot 430 and wedged tightly against the adjacent face 110, 130, 210, 230, 310, 330, 315, 335, 510, 530, 515, 535, and 1032 of the footing form. A hammer may be used to pound in wedge bolt 400 farther and increase compression for a more ridged connection. The convex surface 435 is always placed inside the footing form because the smooth surface does not bond substantially with the cast concrete. The convex head can easily be removed from the concrete with a simple tap from a hammer cracking the minor bond allowing the removal of all corner form pieces. Conversely, the slot 430 of the slotted bolt 440 should always be placed to the outside of footing form corners for easy assembly and removal of wedge bolt 400. Placing slot 430 to the inside where concrete is poured would permanently cement slotted bolt 440 into the footing and make removal of footing forms impossible. Slotted bolt 410, 440 may be manufactured as flat, square, or round shafts if desired.

FIG. 9 illustrates the preferred embodiment of footing form adjustment Lever 600 which serves as a leverage tool to lengthen or shorten footing form assemblages. Lower lever arm 620 is formed as a ridged shaft approximately two feet in length with several attachment channels 630 welded in place perpendicular to the length of lower lever arm 620 along the bottom side 655 for attachment to footing form spacer 1003. Lower lever arm 620 terminates at lower hinge 625 where a hole for receiving hinge pin 650 is drilled in the slightly thicker material of lower hinge 625 to allow rotation of hinge pin 650 while maintaining the strength of the tool 600 as is expected from common construction working tools over time and experiencing normal wear.

Handle hinge 645 also joins to the hinge pin 650. The handle hinge 645 is similar to the lower hinge 625. Handle hinge 645 is joined to lever arm handle 605 which serves to provide leverage to the user of footing form adjustment lever 600 for adjusting the length of previously arranged footing forms. Lever 600 also serves a second purpose of pulling together or apart footing form sections during assembly. Lever arm handle 605 is approximately 3 feet long and sufficiently ridged so as to not bend or break when repeated full force is applied to move the weight of assembled footing forms 1001 where the frictional force produced by steel on steel and steel on earth interactions is present.

Lever arm handle 605 extends upwardly from handle hinge 645 approximately one fourth of the length of handle 605 to horse shoe grip 615 with opposing grip edges which serve to engage adjacent footing form spacer 1003 for pulling together or pushing apart the adjacent forms 1001, 1002. The friction force caused by the abutment of the adjoining forms 1001 requires the additional leverage of footing form adjustment lever 600 to make working with reusable steel footing forms practical and desirable. At the top of lever arm handle is handle grip 640 where a grip material that is comfortable for the hand to grasp is placed to enhance the tool ergonomically.

FIG. 10 illustrates footing form adjustment lever 600 engaged with two adjacent steel footing forms 1001 with the attachment channel 630 engaging one spacer 1003 while the horse shoe grip 615 is engaged with another spacer 1003 of an adjoining footing form section 1001. The lever 600 is positioned to pull or push on the two adjoining footing forms 1001. Pulling on the handle 605 of the lever 600 will pull the two forms 1001 together by forcing one of the forms 1001 to slide over the top of the other form 1001 at the junction 1005 until the desired position is achieved. Pushing on the handle 605 of the lever 600 in the position illustrated will push the two footing form sections apart and make the total length of the abutting forms 1001 longer. 

1. An inside corner mold form for use with a linear static mold form, the combination being used for simultaneously casting a building footing and building wall from a curable material, the inside corner mold form comprising: (a) a first side adapted to abut a liquid material used to cast the building footing and the building wall; (b) a second side, the second side be substantially opposite the first side; (c) a first vertical base extension (515); (d) a second vertical base extension (510), the second vertical base extension being rigidly bonded to and substantially perpendicular to the first vertical base extension; (e) a first sloping side wall (525), the first sloping side wall being integrally formed with the first vertical base extension; (f) a second sloping side wall (520), the second sloping sidewall being integrally formed with the second vertical base extension, the second sloping side wall abutting the first sloping side wall; (g) a first upper vertical extension (535), the second upper vertical extension being integrally formed with the first sloping side wall; and (h) a second upper vertical extension (530), the second upper vertical extension being integrally formed with the second sloping sidewall, the second upper vertical extension abutting the first upper vertical extension such that a liquid material is prevented from passing from the first side to the second side.
 2. The inside corner mold form of claim 1, wherein the first vertical base extension further comprises a substantially planar tab (540), the substantially planar tab being rigidly affixed to the second vertical base extension.
 3. The inside corner mold form of claim 2, wherein the first vertical base extension is formed to include a substantially vertical wall, the substantially planar tab (540) being substantially perpendicular to the vertical wall.
 4. The inside corner mold form of claim 3, wherein the first sloping side wall is substantially planar and resides within a first plane, the first plane forming a first angle with the vertical wall of the first vertical base extension of between ten and eighty degrees.
 5. The inside corner mold form of claim 4, wherein the first sloping side wall is substantially parallel to an inclined wall of an adjacent linear static mold form (1001).
 6. The inside corner mold form of claim 5, further comprising at least one horizontal ledge (340) adapted to support a wall panel.
 7. The inside corner mold form of claim 6, wherein the first upper vertical extension (335) is formed to include a first edge, the horizontal ledge (340) being substantially perpendicular to the first edge.
 8. The inside corner mold form of claim 7, wherein the first sloping side wall (325) terminates at an exterior face of an insulated concrete form.
 9. The inside corner mold form of claim 5 further comprising a tab (550), the tab having a substantially triangular shape and being formed to include a substantially horizontal upper edge, the tab being affixed to each upper vertical extension and positioned to substantially prevent the liquid from passing through a ledge channel formed within the linear static mold form.
 10. The inside corner mold form of claim 9, further comprising a plurality of holes (542, 545) adapted to receive a fastener formed as a shaft (440), the fastener permitting the inside corner mold form to be affixed to a linear static mold form (1001).
 11. The inside corner mold form of claim 10 wherein the fastener is formed to include a slot (430) adapted to receive a wedge bolt
 400. 12. The inside corner mold form of claim 11, wherein the fastener is formed to have a convex head (435) adapted to simplify removal of the fastener (440) from concrete.
 13. An outside corner mold (100, 200) for use with a linear static mold form, the combination being used for simultaneously casting a building footing and building wall from a curable material, the outside corner mold form comprising: (a) a first side adapted to abut a liquid material used to cast the building footing and the building wall; (b) a second side, the second side be substantially opposite the first side; (c) a first vertical base extension (110); (d) a second vertical base extension (210), the second vertical base extension being rigidly bonded to and substantially perpendicular to the first vertical base extension; (e) a first sloping side wall (120), the first sloping side wall being integrally formed with the first vertical base extension; (f) a second sloping side wall (220), the second sloping sidewall being integrally formed with the second vertical base extension, the second sloping side wall abutting the first sloping side wall; (g) a first upper vertical extension (130), the second upper vertical extension being integrally formed with the first sloping side wall; and (h) a second upper vertical extension (230), the second upper vertical extension being integrally formed with the second sloping sidewall, the second upper vertical extension abutting the first upper vertical extension such that a liquid material is prevented from passing from the first side to the second side.
 14. The outside mold corner of claim 13, further comprising a plurality of support ledges (150, 250) adapted to support vertically extending wall panel forms (910, 915).
 15. The outside mold corner of claim 14, further comprising a plurality of holes (135) formed through the second upper vertical extension (230), the holes being adapted to receive a fastener capable of affixing the outside mold corner (200) to a linear static mold form (1001).
 16. The outside mold corner of claim 15, wherein the first vertical base extension (210) is formed to include a first hole (270) and the second vertical base extension (110) is formed to include a tab, the tab being substantially parallel to the first base extension (210), the tab including a second hole (170) that is substantially aligned with the first hole (270).
 17. A method of enhancing the usefulness of linear static mold forms (1001, 1002) used for simultaneously casting a building footing and building wall from a curable material, comprising the steps of: (a) forming a hole in a first static mold form (1001); (b) forming a second hole in a second static mold form; (c) placing the first static mold form in a substantially parallel, spaced apart relationship from a second mold form such that the first and second hole are substantially aligned; (d) forming a plurality of slots within a hollow tube (410); (e) placing the hollow tube through the first hole and the second hole such that a least one slot extends beyond each static mold from; and (f) placing a wedge bolt through a slot extending beyond the static mold from so as to urge the first static mold form toward the second mold form.
 18. The method of claim 17, further comprising the steps of inserting a plurality of tubular spacers (1003) between the first and second static mold forms.
 19. The method of claim 18, further comprising the steps of: (a) forming a lever (600) to include a first shaft (605) and a second shaft (620); (b) attaching a plurality of attachment channels (630) to the second shaft; (c) pivotably interconnecting the first shaft to the second shaft near an end region of each shaft; (d) forming a horseshoe grip (615) on the second shaft; (e) engaging a first spacer (1003) on a first form (1001) with the horseshoe grip (615); (f) engaging a second spacer (1003) on a second form (1001) with at least one of the attachment channels; and (g) pulling the first shaft away from the second shaft so as to cause the first form to move in a first direction, the first direction urging a portion of the first form to overlap a portion of the second form.
 20. The method of claim 19, further comprising the step of pushing the first shaft toward the second shaft so as to cause the first form to move in a second direction, the second direction being substantially opposite to the first direction. 